Exterior wall panel with enhanced interior facing surface

ABSTRACT

An insulation backing for use in a siding product or an insulated siding panel that includes a backing member composed of a closed cell polymeric material. The insulation backing or backing member including a rear face having a planar surface and at least one geometric region that deviates from the planar surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Provisional Patent Application Ser. No. 60/753,152 filed on Dec. 21, 2005.

BACKGROUND

The present invention relates to a sidewall panel such as a siding element for an exterior wall of a building. The invention also relates to a backing member for use with siding. In particular, the invention provides a backing member and/or wall panel with an enhanced drainage plane located on the rear face of a backing member. The drainage plane can be composed of various geometric configurations sufficient to allow water to more efficiently dissipate from the surfaces within the exterior wall of a building.

The construction industry, both new construction and remodeling, is increasingly confronted with problems associated with the buildup of moisture on surfaces within exterior walls. The moisture buildup can cause degradation of the exterior wall material and may result in growth of various types of molds. Such molds are frequently blamed for causing serious respiratory illnesses and other health conditions in humans and animals. Thus, it is desirable to provide material that minimizes the opportunity for mold growth. Building codes have long required that exterior walls be permeable so that moisture can escape in the event that moisture is introduced or established in the wall. In spite of serious efforts to prevent moisture buildup on exterior walls, occasionally water can find its way into these regions. Water introduction may be due to poor installation, inadequate flashing, leaking pipes, or irregularities in building practice. In some cases, water can be found or introduced into the exterior wall system in such large quantities that it overwhelms the system. In other words, the exterior wall material and system simply cannot dissipate the moisture fast enough to prevent or minimize the conditions that can promote mold growth and dry rot of the wooden framing. Thus, it is desirable to provide a system whereby moisture can be readily dissipated or removed from the exterior wall system.

Exterior wall systems also must provide appropriate insulation characteristics to minimize undesired heat loss or heat dissipation. Such systems can include various backing or liner members adapted to be interposed between waterproof or essentially waterproof siding material and the exterior wall. It is desirable to provide a backing member and/or an integrated panel system having enhanced drainage characteristics.

SUMMARY

Disclosed herein is an insulated siding panel for mounting on a wall that includes a backing member and a siding layer affixed to a backing member. The backing member includes a rear face and an opposed front face. The backing member is composed of closed cells of expanded polymeric foam or cellular plastic with the rear face of the backing member having a planar surface and at least one geometric region defined thereon that deviates from the planar surface. The backing member may be shape-molded.

Also disclosed herein is a shape-molded insulation backing element for use with an insulated siding product. The insulation backing element comprises a central core composed of a closed cell expanded polymeric foam. The outer surface of the insulation backing element will have at least one outer surface region that exhibits a tough, smooth skin composed of closed-cell polymeric foam. The insulation backing element has a front face region and a rear face region in contiguous contact with the central core and composed of closed cell expanded polymeric foam. The rear face region is adapted to overly at least one wall and includes at least one geometric element defined herein. The insulation backing element may be shape-molded

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts through the several views, and wherein,

FIG. 1 is a front perspective view of a composite siding panel including an enhanced drainage plane as disclosed herein;

FIG. 2 is a rear exploded perspective view of an insulation backing for use with a siding product including an enhanced drainage plane as disclosed herein;

FIGS. 3A through 3D are rear plan views of the rear face or face region of FIG. 1 or 2 having various grooves and/or channels defining various patterns.

FIGS. 4A through 4D are rear plan views of insulation backing or the backing member of a panel of FIG. 1 or 2 having at least one protruding geometric element in combination with at least one groove or channel; AND

FIGS. 5A through 5D are rear plan views of the insulation backing or backing member of a panel in FIGS. 1 and 2 showing various nonlimiting examples of protruding geometric elements defined therein.

DESCRIPTION

Disclosed herein is an insulated siding panel having an enhanced drainage plane positioned on its rear face. The construction market utilizes a large number of insulated siding panel devices. One nonlimiting example of insulated siding panel devices includes the device depicted in FIG. 1. As broadly disclosed herein, the insulated siding panel 10 depicted in FIG. 1 includes a backing member 14 that can be attached or mounted to a siding layer 12. The siding layer 12 can be a contoured siding product and/or the backing member can be contoured, either complimentarily to the siding layer or contoured to provide or form geometric elements to the applied siding layer.

The backing member 14 may be composed of a shape-molded polymeric material in whole or in part as desired or required. The term “shape-molded” as used herein is taken to mean that the contours and/or outer surfaces of one or more faces of the backing member 14 are fabricated by a molding operation or operations. Such molding operations will generally impart contours and geometric regions to the backing member 14. These contours and geometric regions typically possess a tough smooth outer skin. Nonlimiting examples of shape-molding processes that can impart such surface characteristics include molding processes employed with encapsulated cellular foam materials.

It is contemplated that one or more faces can be composed in whole or in part of shape-molded surfaces as desired or required. Where less than all faces are characterized by shape-molded surfaces, it is contemplated that at minimum the rear face will exhibit at least a partially shape-molded surface. Where the backing member 14 has surfaces that are not shape-molded, the nonshape-molded surfaces and any contours thereon can be produced by any suitable method. Nonlimiting examples of such methods include wire-cutting.

Thus it is contemplated that the shape-molding can provide or produce a finished product. However, it is also contemplated that the shape-molding process can be employed in combination with other cutting or formation process to provide additional features.

It is contemplated that the rear face of the backing member 14 will be shape-molded in whole or in part. It is contemplated that, in various embodiments, the backing member 14 can have portions of at least front and rear faces that are shape-molded. In other embodiments it is contemplated that, in addition to shape-molding on the front and rear surfaces, various other surfaces such as side edges and top and bottom ends can be shape-molded, as desired or required.

The siding layer 12 can be affixed to the backing member 14 in a wide variety of fashions. Such attachment fashions include, but need not be limited to, adhesive bonding, heat bonding, chemical bonding, interlocking of complimentary surfaces, mechanical fasteners, and/or the insertion or “dropping in” of the backing member 14 on site.

Also disclosed herein is a shape-molded insulation backing 114 for use with a suitable siding product 112. The shape-molded insulation backing 114 can have characteristics as previously described with backing member 14. It is contemplated that at least a portion of at least one face of the shape-molded insulation backing member 114 will possess a tough, smooth skin.

It is contemplated that various cellular plastics can be employed as the material for the backing member 14 or insulation backing 114 disclosed herein. As used herein, the term(s) “cellular foam” or “cellular foam plastic” are taken to mean a plastic or polymeric material with numerous cells of trapped air distributed throughout its mass. Nonlimiting examples of such materials can also be referred to as expanded plastics or foamed plastics with expanded polystyrene being but one nonlimiting example.

“Polystyrene foam” as used herein refers to cellular foam plastic made from polystyrene typically by incorporation of a volatile blowing agent into polystyrene beads as they are polymerized or afterward. In expanded polystyrene, beads of polystyrene are first pre-expanded and allowed to rest for a suitable interval, then molded in a closed steam-heated mold to produce closed-cell foams. The size and density of the closed cells can vary from application to application depending on the characteristics required. Thus it is contemplated that cell density can be varied by suitable processing parameters to produce foam size suitable for the desired end use application. Variation in characteristics attributable to density can include, but need not be limited to, insulation capacity, dent or break resistance, and the like.

As depicted in FIGS. 2, 3, and 4, backing member 14 or the insulation backing 114, respectively, have a rear face 30, 130, and an opposed front face 32, 132. The rear face of the shape-molded backing member 14 or shape-molded insulation backing 114 defines a planar surface having at least one geometric element or region that deviates from the planar surface either positively or negatively. The geometric element can be of any suitable shape, size, and/or configuration and can either extend outward from the surface of the rear face region 30, 130, or be depressed into the rear face region 30, 130. As depicted in FIGS. 2, 3, and 4, the geometric element can be at least one groove or channel 34, 134, or an outward projection such as ridge 36, 136. The geometric element such as groove or channel 34, 134, and/or ridge 36, 136, can have any suitable shape or configuration. The disclosure herein contemplates shape-molded backing members 14 or shape-molded insulation backing elements 114 that have either depressed geometric elements, projecting geometric elements, or a combination of both.

The geometric element can have any suitable contour desired or required and can be configured into any suitable pattern or orientation as desired or required. As illustrated in FIGS. 2 and 3D, the grooves 34, 134 make up a grid network. Grooves 34, 134 can be positioned in interlocking relationship in a manner that facilitates drainage of any accumulated or condensed liquid through the grooves away from the closed-cell backing member 14 or closed-cell insulation backing element 114. As shown in FIGS. 2 and 3D, the grooves 34, 134 can be positioned in a diamond pattern. Other configurations are contemplated. The water can be conveyed by gravity through the grid made up of drainage grooves 34, 134 to a suitable exit or egress point. Egress can be from any suitable location. As depicted in the drawing figure, a series of drainage exit grooves 40, 140 can be positioned at the lowermost region of the backing member as in the layered lower region 42, 142. The drainage grooves 34, 134 can communicate with drainage exit grooves 40, 140 in order to convey collected water or condensate away from the rear face 30, 130 of the backing member.

It is to be understood that the cellular plastic employed herein is capable of transmission of discrete volumes of water vapor through the closed-cell plastic material to external surfaces and faces of the closed-cell backing member 14 or closed-cell insulation backing element 114 for transmission or dispersion to the external environment. In certain situations, liquid condensate can form between the wall and associated siding element such as siding element 10. It is understood that condensed liquid as opposed to water vapor does not easily transpire through the closed-cell cellular plastic. Liquid condensate is conveyed through channels, grooves, and suitable surfaces defined in the face to a suitable exit point where it can drain or evaporate.

As depicted in FIG. 3A, the drainage grooves 34 can be arranged in a diamond pattern at roughly a 30° angle from a vertical orientation. It is to be understood that this configuration is illustrative of various configurations and patterns that can be established. Thus, grooves 34, 134 can be positioned at a wide variety of angles to one another and in a wide variety of patterns.

With reference to FIGS. 3B-3D, there is illustrated a plurality of examples of groove arrangements. These arrangements can include diagonal patterns such as those illustrated in FIG. 3B, vertical patterns as illustrated in FIG. 3C, and/or square patterns with drainage grooves positioned at an angle of 45° from vertical orientation as illustrated in FIG. 3D.

The number of grooves 34, 134 employed can be any number necessary to provide an appropriate drainage plane for the shape-molded backing member 14, 114, or shape-molded backing element 114. Additionally, the depth of the grooves is that sufficient to provide appropriate drainage. By way of nonlimiting example, it is contemplated that grooves having a maximum depth between 1/16 inch and ½ inch can be placed in spaced relationship to one another. By way of nonlimiting example, the interval between grooves can be 0.1 to 5 inches.

Turning now to FIGS. 4A through 4D, there is depicted a variety of configurations for the rear surface of the shape-molded backing member 14, or shape-molded backing element 114, including a combination of grooves 34, and protrusions 36. It is contemplated that the protrusions can have any suitable shape or configuration. It is also contemplated that the protrusions 36 can be positioned as desired or required. As a nonlimiting example, protrusions 36 are positioned in the diamond grid as shown in FIG. 4A. In FIG. 4B, the protrusions are a series of elongated ridges positioned proximate to the diagonal grooves in FIG. 4B, or centrally between the grooves 34 in FIG. 4C. It is also contemplated that protrusions 36 can be located proximate to suitable corner members as in FIG. 4D. Other suitable configurations and combinations of grooves 34, 134 and protrusions 36, 136 are also contemplated.

It is also contemplated that the shape-molded backing member 14, or shape-molded insulation backing element 114 can be configured solely with protrusions 36, 136. Nonlimiting examples of such configurations are set forth in FIGS. 5A through 5D. As depicted in FIG. 5A, the rear face 30 can include outwardly protruding members 36 positioned in external corners of the member. In FIG. 5A additional protrusions 36, are located in the central region of the rear face. In FIG. 5B, the outward protrusions are similarly positioned. However, the outward protrusions 36 are shaped as diamond members. It is contemplated that the shape, location, and size of the protrusion can be any configuration suitable for maintaining the planar portion of rear face 30 away from the associated wall. The distance or standoff maintained will be that sufficient to facilitate drainage. Other nonlimiting examples of such protrusions include ridges such as vertical ridges shown in FIG. 5C and random spherical elements shown in FIG. 5D. It is also contemplated that indentations and/or protrusions can be utilized and positioned in a manner to depict brand names, instructions, orientation aids, or the like.

The geometric regions 34, 36, 134, 136 are composed of closed cell expanded polymeric foam. It is contemplated that the outer surface of the respective geometric regions is characterized by a surface defined by closed polymeric cells. It is contemplated that the surface of the geometric region will be characterized by intact, unruptured cells thereby defining a smooth surface that facilitates transfer of water therethrough. The outer surface of the geometric regions 34, 134, 36, 136 is characterized by a tough smooth skin. The skin is one that provides suitable compressive and/or flexural strength to the geometric region. This is typically a skin structure imparted by the shape-molding process. The tough smooth skin of the outer surface of geometric regions 34, 134, 36, 136 can be contiguous to the surface region of the surrounding planar regions of rear face 30, 130.

Heretofore, geometric regions present in backing members were defined by surfaces produced by cut or ruptured cells. Such surfaces possessed numerous concavities in which water could collect and be held. Without being bound to any theory, it is believed that the closed cell smooth surface reduces the surface tension between water and the geometric surface to facilitate water transfer.

As defined herein, it is contemplated that at least the geometric regions have a smooth closed cell surface. It is also contemplated that, in some embodiments, planar regions surrounding the geometric regions may have a smooth surface defined by closed expanded polymeric cells. Where desired or required, it is contemplated that the entire planar surface can be a smooth, closed-cell surface characterized by the tough, smooth skin.

The backing member 14 and insulation backing 114 can also include an opposed front face 32, 132. The opposed front face cellular polymeric material surface is characterized by closed polymeric cells. The material surface can be defined by a tough smooth skin typically formed in the shape-molding process. It is also contemplated that surfaces of the side edges and/or upper and lower end forms can be formed of closed cell polymeric material and can have the tough smooth skin described previously.

It is contemplated that the closed polymeric cells in the shape-molded backing member 14 or shape-molded insulation backing element 114 may have an essentially uniform volumetric size throughout the respective members. However, it is within the purview of this disclosure to have variation of the cell volume and configuration between the various regions of the member 14, 114. Thus, it is contemplated that the shape-molded backing member 14, or shape-molded insulation backing element 114 can include a central core having cells of a certain size and density. Where desired or required, the cells in the region proximate to the rear face 30 and/or front face 32 can be compressed and/or elongated to form a denser skin-like region along the respective surface or surfaces.

The front face 32, 132 can be configured in any suitable shape or contour. Where the shape-molded backing member 14, or shape-molded insulation backing element 114 is to be integrated into an exterior siding panel, it is contemplated that the front face may include at least one suitable outwardly projecting extension extending vertically along the first side of the backing member or insulation backing to roughly approximate the configuration of siding overlap.

Where desired or required, it is contemplated that the shape-molded backing member 14 or shape-molded insulation backing 114 can be composed of closed cell polymeric material having two or more different densities at different locations in the shape-molded backing member 14, or shape-molded insulation backing element 114. It is contemplated that higher density material will be located in regions where greater localized panel strength is required. Nonlimiting examples of such regions are areas prone to abuse and damage such as overhangs, protrusions, and the like. As used herein, strength can be measured and quantified as characteristics including, but not limited to, compressive strength, flexural modulus, and the like. By way of nonlimiting example, it is contemplated that the panel can have a general density of 1 lb per square foot while selected regions have elevated densities of 2 lb per square foot or greater.

Where desired or required, the backing member 14, or insulation backing 114 can include a suitable detent 40 extending vertically inward along a lower side to position and receive a suitable mating siding panel.

It is contemplated that the shape-molded backing member 14 can be affixed to a suitable siding layer 12 in a wide variety of fashions. Such attachment can include, but is not limited to, adhesives, chemical bonding, heat bonding, interlocking of complimentary surfaces, fastening, and the like. It is also contemplated that the backing member 14 or insulation backing 14 can be “dropped in” to the siding element at the job site.

The siding layer 12 may be composed of any suitable polymeric, metallic, cementious or composite material. It is contemplated that the siding material will be one capable of providing suitable environmental resistance and durability. The siding material will have sufficient thickness to maintain its shape and contour throughout the useful life of the associated siding panel when integrated with a suitable backing member. Appropriate materials include, but are not limited to, polymeric vinyls and the like. Other nonlimiting examples of suitable materials include various cementious components. It is contemplated that the siding layer 12 will be suitably contoured to conform to the contours of the shape-molded backing member 14. The correspondence in respective contours can be exact. However, it is contemplated that the contours can vary depending upon the nature of the end product.

It is contemplated that the shape-molded backing member 14, or insulation backing 114 can have a length of between 36 inches and 240 inches and will typically have lengths of 144 to 240 inches, as desired or required. The resulting element and/or associated insulated siding panel 10 will be essentially straight and free from camber and bowing.

The backing member 14, or shape-molded insulation backing element 114 can have a suitable width. Nonlimiting examples of suitable widths would be between 7 and 48 inches, with typical widths between 8 and 36 inches in various applications.

The shape-molded backing member 14, or shape-molded insulation backing element 114 can have a suitable thickness such that the resulting unit 10 has a thickness between 250 thousandths of an inch and 4 inches.

The panels 10 can be used in suitable combination to be affixed to and cover the desired wall or portions thereof. When installed, it is contemplated that the various panels 10 will contact or abut one another such that the various channels or grooves connect or communicate with one another or with suitable drainage vents positioned in the siding layer 12.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law. 

1. An insulated siding panel for mounting on a wall, the panel comprising: a backing member having a rear face and an opposed front face, the backing member composed of a closed cell polymeric material, the rear face of the backing member including a planar surface and at least one region that deviates geometrically from the planar surface; and a siding layer affixed to the front face of the backing member.
 2. The panel of claim 1, wherein the geometric region on the rear face of the backing member includes at least one element extending outward from the planar surface.
 3. The panel of claim 2, wherein at least one of the at least one outwardly extending element includes an elongated ridge.
 4. The panel of claim 2, wherein an outer surface of the outwardly extending element is defined by closed polymeric cells.
 5. The panel of claim 2, wherein the backing member further comprises first and second edges adjoining the rear face, the outwardly extending element extending laterally along the planar surface from the first edge to the second edge.
 6. The panel of claim 2 wherein the outwardly extending element defines a grid pattern.
 7. The panel of claim 1 wherein the geometric region on the rear face of the backing member includes at least one element forming a depression in the planar surface.
 8. The panel of claim 7, wherein the depression is in the form of at least one of a groove and a channel defined in the planar surface of the backing member.
 9. The panel of claim 8, wherein the grooves and channels define a grid pattern.
 10. The panel of claim 7, wherein an outer surface of the depression is defined by closed polymeric cells.
 11. The panel of claim 7, wherein the depression extends laterally along the planar surface from a first edge to a second edge of the panel.
 12. The panel of claim 1, wherein an outer surface of the geometric region is defined by closed polymeric cells.
 13. The panel of claim 1, wherein an outer surface of the front face of the panel is defined by closed polymeric cells.
 14. The panel of claim 1 further comprising at least one raised protrusion extending from the front face proximate a first edge of the panel; and at least one detent formed in the back face proximate a second edge of the panel for receiving the raised protrusion extending from the front face when two separate panels are joined together.
 15. The panel of claim 1, wherein the surface contour of the front face substantially coincides with an inner contour of the siding layer.
 16. The panel of claim 1 wherein the panel has a length between 4 and 24 feet.
 17. An insulation backing for use with a siding product, the insulation backing comprising: a central core composed of a closed cell expanded polymeric foam; a front face region adapted to contact the siding product, the front face region in contiguous contact with the central core and composed of closed cell expanded polymeric foam; and a rear face region in contiguous contact with the expanded foam central core and composed of closed cell expanded polymeric foam, wherein the rear face region includes at least one geometric element defined therein.
 18. The insulation backing of claim 17 wherein the geometric element is at least one of a groove, channel, and outward projection.
 19. The insulation backing of claim 18, wherein at least one of the groove, channel, and outward projection extends laterally along the rear face from a first edge to a second edge of the insulation backing.
 20. The insulation backing of claim 17, wherein the geometric element defines a grid pattern. 